Control valves for heaters and fireplace devices

ABSTRACT

In certain embodiments, a control valve assembly for gas heaters and gas fireplace devices includes a housing. The housing can define an inlet for accepting fuel from a fuel source, a first outlet for delivering fuel to an oxygen depletion sensor, and a second outlet for delivering fuel to a burner. The assembly can include a valve body configured to selectively provide fluid communication between the inlet and one or more of the first outlet and the second outlet, and can include an actuator configured to move the valve body relative to the housing. The actuator can be configured to transition between a resting state and a displaced state. The assembly can include an igniter that includes a sensor, the igniter electrically coupled with an electrode and configured to repeatedly activate the electrode when the sensor senses that the actuator is in the displaced state. The assembly can include a shutoff valve electrically coupled with the oxygen depletion sensor and configured to operate in response to an electrical quantity communicated by the oxygen depletion sensor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. §119(e) of U.S.Provisional Application No. 60/871,760, filed Dec. 22, 2006, titledCONTROL VALVES FOR HEATERS AND FIREPLACE DEVICES; the entire contents ofwhich are hereby incorporated by reference herein and made a part ofthis specification.

BACKGROUND

1. Field of the Inventions

Certain embodiments disclosed herein relate generally to heatingdevices, and relate more specifically to fluid-fueled heating devices.

2. Description of the Related Art

Many varieties of heaters, fireplaces, stoves, and other heating devicesutilize pressurized, combustible fuels. Some such devices can includecontrol valves that regulate fluid flow through the devices. However,such control valves have various limitations and disadvantages.

SUMMARY OF THE INVENTIONS

In certain embodiments, a control valve assembly for gas heaters and gasfireplace devices includes a housing. The housing can define an inletfor accepting fuel from a fuel source, a first outlet for deliveringfuel to an oxygen depletion sensor, and a second outlet for deliveringfuel to a burner. The assembly can include a valve body configured toselectively provide fluid communication between the inlet and one ormore of the first outlet and the second outlet, and can include anactuator configured to move the valve body relative to the housing. Theactuator can be configured to transition between a resting state and adisplaced state. The assembly can include an igniter that includes asensor, the igniter electrically coupled with an electrode andconfigured to repeatedly activate the electrode when the sensor sensesthat the actuator is in the displaced state. The assembly can include ashutoff valve electrically coupled with the oxygen depletion sensor andconfigured to operate in response to an electrical quantity communicatedby the oxygen depletion sensor.

In some embodiments, a control valve assembly for gas heaters, gas loginserts and gas fireplaces includes a housing. The housing can define aninlet for accepting fuel from a fuel source, a first outlet fordelivering fuel to an oxygen depletion sensor, and a second outlet fordelivering fuel to a burner. The housing can further define a first fuelpath in fluid communication with the second outlet and a second fuelpath in fluid communication with the second outlet. The assembly caninclude a valve body configured to selectively provide fluidcommunication between the inlet and one or more of the first outlet andthe second outlet. The valve body can be configured to provide fluidcommunication between the inlet and the second outlet via either thefirst fuel path or the second fuel path. The assembly can include afirst shutoff valve electrically coupled with the oxygen depletionsensor and configured to operate in response to an electrical quantitycommunicated by the oxygen depletion sensor. The assembly can alsoinclude a second shutoff valve configured to selectively prevent fluidcommunication between the valve body and the second outlet via the firstfuel path.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments are depicted in the accompanying drawings forillustrative purposes, and should in no way be interpreted as limitingthe scope of the inventions.

FIG. 1 is a perspective cutaway view of a portion of an embodiment of aheater configured to operate using either a first fuel source or asecond fuel source.

FIG. 2 is a perspective cutaway view of the heater of FIG. 1.

FIG. 3 is a bottom perspective view of an embodiment of a pressureregulator configured to couple with either the first fuel source or thesecond fuel source.

FIG. 4 is a back elevation view of the pressure regulator of FIG. 3.

FIG. 5 is a bottom plan view of the pressure regulator of FIG. 3.

FIG. 6 is a cross-sectional view of the pressure regulator of FIG. 3taken along the line 6-6 in FIG. 5.

FIG. 7 is a top perspective view of the pressure regulator of FIG. 3.

FIG. 8 is a perspective view of an embodiment of a heat control valve.

FIG. 9 is a perspective view of one embodiment of a fluid flowcontroller comprising two valves.

FIG. 10 is a bottom plan view of the fluid flow controller of FIG. 9.

FIG. 11 is a cross-sectional view of the fluid flow controller of FIG.9.

FIG. 12 is a perspective view of an embodiment of a nozzle comprisingtwo inputs, two outputs, and two pressure chambers.

FIG. 13 is a cross-sectional view of the nozzle of FIG. 12 taken alongthe line 13-13 in FIG. 14.

FIG. 14 is a top plan view of the nozzle of FIG. 12.

FIG. 15 is a perspective view of an embodiment of an oxygen depletionsensor (ODS) comprising two injectors and two nozzles.

FIG. 16 is a front plan view of the ODS of FIG. 15.

FIG. 17 is a top plan view of the ODS of FIG. 15.

FIG. 18 is a perspective view of another embodiment of an ODS comprisingtwo injectors and two nozzles.

FIG. 19 is a perspective cutaway view of a portion of an embodiment of aheater comprising a control valve assembly with certain features andaspects of the present invention.

FIG. 20 is a perspective view of an embodiment of a control valveassembly compatible with the heater illustrated in FIG. 19.

FIG. 21 is a cross-sectional view of the control valve assemblyillustrated in FIG. 19 shown in an “off” configuration.

FIG. 22A is a partial cross-sectional view of the control valve assemblyillustrated in FIG. 19 taken along the view line 22-22 shown in FIG. 21.

FIG. 22B is a partial cross-sectional view of another embodiment of acontrol valve assembly.

FIG. 23 is a cross-sectional view of the control valve assemblyillustrated in FIG. 19 shown in a “pilot” configuration.

FIG. 24 is a cross-sectional view of the control valve assemblyillustrated in FIG. 19 shown in a “manual” configuraiton.

FIG. 25 is a cross-sectional view of the control valve assemblyillustrated in FIG. 19 shown in an “automatic” configuraiton.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Many varieties of space heaters, fireplaces, stoves, fireplace inserts,gas logs, and other heat-producing devices employ combustible fuels,such as liquid propane and natural gas. These devices generally aredesigned to operate with a single fuel type at a specific pressure. Forexample, some gas heaters that are configured to be installed on a wallor a floor operate with natural gas at a pressure in a range from about3 inches of water column to about 6 inches of water column, while othersoperate with liquid propane at a pressure in a range from about 8 inchesof water column to about 12 inches of water column.

In many instances, the operability of such devices with only a singlefuel source is disadvantageous for distributors, retailers, and/orconsumers. For example, retail stores often try to predict the demandfor natural gas units versus liquid propane units over a given winterseason, and accordingly stock their shelves and/or warehouses with apercentage of each variety of heating unit. Should such predictionsprove incorrect, stores can be left with unsold units when the demandfor one type of heater was less than expected, while some potentialcustomers can be left waiting through shipping delays or even be turnedaway empty-handed when the demand for one type of heater was greaterthan expected. Either case can result in financial and other costs tothe stores. Additionally, some consumers can be disappointed to discoverthat the styles or models of stoves or fireplaces with which they wishto improve their homes are incompatible with the fuel sources with whichtheir homes are serviced.

Certain advantageous embodiments disclosed herein reduce or eliminatethese and other problems associated with heating devices that operatewith only a single type of fuel source. Furthermore, although theembodiments described hereafter are presented in the context ofvent-free heating systems, the apparatus and devices disclosed andenabled herein can benefit a wide variety of other applications.

FIG. 1 illustrates one embodiment of a heater 10. In variousembodiments, the heater 10 is a vent-free infrared heater, a vent-freeblue flame heater, or some other variety of heater, such as a directvent heater. Some embodiments include stoves, fireplaces, and gas logs.Other configurations are also possible for the heater 10. In manyembodiments, the heater 10 is configured to be mounted to a wall or afloor or to otherwise rest in a substantially static position. In otherembodiments, the heater 10 is configured to move within a limited range.In still other embodiments, the heater 10 is portable.

In certain embodiments, the heater 10 comprises a housing 20. Thehousing 20 can include metal or some other suitable material forproviding structure to the heater 10 without melting or otherwisedeforming in a heated environment. In some embodiments, the housing 20comprises a window 22 through which heated air and/or radiant energy canpass. In further embodiments, the housing 20 comprises one or moreintake vents 24 through which air can flow into the heater 10. In someembodiments, the frame comprises outlet vents 26 through which heatedair can flow out of the heater 10.

With reference to FIG. 2, in certain embodiments, the heater 10 includesa regulator 120. In some embodiments, the regulator 120 is coupled withan output line or intake line, conduit, or pipe 122. The intake pipe 122can be coupled with a heater control valve 130, which, in someembodiments, includes a knob 132. In many embodiments, the heatercontrol valve 130 is coupled to a fuel supply pipe 124 and an oxygendepletion sensor (ODS) pipe 126, each of which can be coupled with afluid flow controller 140. In some embodiments, the fluid flowcontroller 140 is coupled with a first nozzle line 141, a second nozzleline 142, a first ODS line 143, and a second ODS line 144. In someembodiments, the first and the second nozzle lines 141, 142 are coupledwith a nozzle 160, and the first and the second ODS lines 143, 144 arecoupled with an ODS 180. In some embodiments, the ODS comprises athermocouple 182, which can be coupled with the heater control valve130, and an igniter line 184, which can be coupled with an igniterswitch 186. Each of the pipes 122, 124, and 126 and the lines 141-144can define a fluid passageway or flow channel through which a fluid canmove or flow.

In some embodiments, the heater 10 comprises a combustion chamber 190.In some embodiments, the ODS 180 is mounted to the combustion chamber190, as shown in the illustrated embodiment. In further embodiments, thenozzle 160 is positioned to discharge a fluid, which may be a gas,liquid, or combination thereof into the combustion chamber 190. Forpurposes of brevity, recitation of the term “gas or liquid” hereaftershall also include the possibility of a combination of a gas and aliquid. In addition, as used herein, the term “fluid” is a broad termused in its ordinary sense, and includes materials or substances capableof fluid flow, such as gases, liquids, and combinations thereof.

In certain preferred embodiments, either a first or a second fluid isintroduced into the heater 10 through the regulator 120. In certainembodiments, the first or the second fluid proceeds from the regulator120 through the intake pipe 122 to the heater control valve 130. In someembodiments, the heater control valve 130 can permit a portion of thefirst or the second fluid to flow into the fuel supply pipe 124 andpermit another portion of the first or the second fluid to flow into theODS pipe 126, as described in further detail below.

In certain embodiments, the first or the second fluid can proceed to thefluid flow controller 140. In many embodiments, the fluid flowcontroller 140 is configured to channel the respective portions of thefirst fluid from the fuel supply pipe 124 to the first nozzle line 141and from the ODS pipe 126 to the first ODS line 143 when the fluid flowcontroller 140 is in a first state, and is configured to channel therespective portions of the second fluid from the fuel supply pipe 124 tothe second nozzle line 142 and from the ODS pipe 126 to the second ODSline 144 when the fluid flow controller 140 is in a second state.

In certain embodiments, when the fluid flow controller 140 is in thefirst state, a portion of the first fluid proceeds through the firstnozzle line 141, through the nozzle 160 and is delivered to thecombustion chamber 190, and a portion of the first fluid proceedsthrough the first ODS line 143 to the ODS 180. Similarly, when the fluidflow controller 140 is in the second state, a portion of the secondfluid proceeds through the nozzle 160 and another portion proceeds tothe ODS 180. As discussed in more detail below, other configurations arealso possible.

With reference to FIGS. 3-7, certain embodiments of the pressureregulator 120 will now be described. FIGS. 3-7 depict different views ofone embodiment of the pressure regulator 120. The regulator 120desirably provides an adaptable and versatile system and mechanism whichallows at least two fuel sources to be selectively and independentlyutilized with the heater 10. In some embodiments, the fuel sourcescomprise natural gas and propane, which in some instances can beprovided by a utility company or distributed in portable tanks orvessels.

In certain embodiments, the heater 10 and/or the regulator 120 arepreset at the manufacturing site, factory, or retailer to operate withselected fuel sources. As discussed below, in many embodiments, theregulator 120 includes one or more caps 231 to prevent consumers fromaltering the pressure settings selected by the manufacturer. Optionally,the heater 10 and/or the regulator 120 can be configured to allow aninstallation technician and/or user or customer to adjust the heater 10and/or the regulator 120 to selectively regulate the heater unit for aparticular fuel source.

In many embodiments, the regulator 120 comprises a first, upper, or topportion or section 212 sealingly engaged with a second, lower, or bottomportion or section 214. In some embodiments, a flexible diaphragm 216 orthe like is positioned generally between the two portions 212, 214 toprovide a substantially airtight engagement and generally define ahousing or body portion 218 of the second portion 212 with the housing218 also being sealed from the first portion 212. In some embodiments,the regulator 120 comprises more than one diaphragm 216 for the samepurpose.

In certain embodiments, the first and second portions 212, 214 anddiaphragm 216 comprise a plurality of holes or passages 228. In someembodiments, a number of the passages 228 are aligned to receive a pin,bolt, screw, or other fastener to securely and sealingly fasten togetherthe first and second portions 212, 214. Other fasteners such as, but notlimited to, clamps, locks, rivet assemblies, or adhesives may beefficaciously used.

In some embodiments, the regulator 120 comprises two selectively andindependently operable pressure regulators or actuators 220 and 222which are independently operated depending on the fuel source, such as,but not limited to, natural gas and propane. In some embodiments, thefirst pressure regulator 220 comprises a first spring-loaded valve orvalve assembly 224 and the second pressure regulator 222 comprises asecond spring-loaded valve or valve assembly 226.

In certain embodiments, the second portion 214 comprises a first fluidopening, connector, coupler, port, or inlet 230 configured to be coupledto a first fuel source. In further embodiments, the second portion 214comprises a second fluid opening, connector, coupler, port, or inlet 232configured to be coupled to a second fuel source. In some embodiments,the second connector 232 is threaded. In some embodiments, the firstconnector 230 and/or the first fuel source comprises liquid propane andthe second fuel source comprises natural gas, or vice versa. The fuelsources can efficaciously comprise a gas, a liquid, or a combinationthereof.

In certain embodiments, the second portion 214 further comprises a thirdfluid opening, connector, port, or outlet 234 configured to be coupledwith the intake pipe 122 of the heater 10. In some embodiments, theconnector 234 comprises threads for engaging the intake pipe 122. Otherconnection interfaces may also be used.

In some embodiments, the housing 218 of the second portion 214 definesat least a portion of a first input channel or passage 236, a secondinput channel or passage 238, and an output channel or passage 240. Inmany embodiments, the first input channel 236 is in fluid communicationwith the first connector 230, the second input channel 238 is in fluidcommunication with the second connector 232, and the output channel 240is in fluid communication with the third connector 234.

In certain embodiments, the output channel 240 is in fluid communicationwith a chamber 242 of the housing 218 and the intake pipe 122 of theheater 10. In some embodiments, the input channels 236, 238 areselectively and independently in fluid communication with the chamber242 and a fuel source depending on the particular fuel being utilizedfor heating.

In one embodiment, when the fuel comprises natural gas, the second inputconnector 232 is sealingly plugged by a plug or cap 233 (see FIG. 7)while the first input connector 230 is connected to and in fluidcommunication with a fuel source that provides natural gas forcombustion and heating. In certain embodiments, the cap 233 comprisesthreads or some other suitable fastening interface for engaging theconnector 232. The natural gas flows in through the first input channel236 into the chamber 242 and out of the chamber 242 through the outputchannel 240 and into the intake pipe 122 of the heater 10.

In another embodiment, when the fuel comprises propane, the first inputconnector 230 is sealingly plugged by a the plug or cap 233 while thesecond input connector 232 is connected to and in fluid communicationwith a fuel source that provides propane for combustion and heating. Thepropane flows in through the second input channel 238 into the chamber242 and out of the chamber 242 through the output channel 240 and intothe intake pipe 122 of the heater 10. As one having skill in the artwould appreciate, when the cap 233 is coupled with either the firstinput connector 230 or the second input connector 232 prior to packagingor shipment of the heater 10, it can have the added advantage of helpingconsumers distinguish the first input connector 230 from the secondinput connector 232

In some embodiments, the regulator 120 comprises a single inputconnector that leads to the first input channel 236 and the second inputchannel 238. In certain of such embodiments, either a first pressurizedsource of liquid or gas or a second pressurized source of liquid or gascan be coupled with the same input connector. In certain of suchembodiments, a valve or other device is employed to seal one of thefirst input channel 236 or the second input channel 238 while leavingthe remaining desired input channel 236, 238 open for fluid flow.

In certain embodiments, the second portion 214 comprises a plurality ofconnection or mounting members or elements 244 that facilitate mountingof the regulator 120 to a suitable surface of the heater 10. Theconnection members 244 can comprise threads or other suitable interfacesfor engaging pins, bolts, screws, or other fasteners to securely mountthe regulator 120. Other connectors or connecting devices such as, butnot limited to, clamps, locks, rivet assemblies, and adhesives may beefficaciously used, as needed or desired.

In certain embodiments, the first portion 212 comprises a first bonnet246, a second bonnet 248, a first spring or resilient biasing member 250positioned in the bonnet 246, a second spring or resilient biasingmember 252 positioned in the bonnet 248, a first pressure adjusting ortensioning screw 254 for tensioning the spring 250, a second pressureadjusting or tensioning screw 256 for tensioning the spring 252 andfirst and second plunger assemblies 258 and 260 which extend into thehousing 218 of the second portion 214. In some embodiments, the springs250, 252 comprise steel wire. In some embodiments, at least one of thepressure adjusting or tensioning screws 254, 256 may be tensioned toregulate the pressure of the incoming fuel depending on whether thefirst or second fuel source is utilized. In some embodiments, theappropriate pressure adjusting or tensioning screws 254, 256 aredesirably tensioned by a predetermined amount at the factory ormanufacturing facility to provide a preset pressure or pressure range.In other embodiments, this may be accomplished by a technician whoinstalls the heater 10. In many embodiments, caps 231 are placed overthe screws 254, 256 to prevent consumers from altering the presetpressure settings.

In certain embodiments, the first plunger assembly 258 generallycomprises a first diaphragm plate or seat 262 which seats the firstspring 250, a first washer 264 and a movable first plunger or valve stem266 that extends into the housing 218 of the second portion 214. Thefirst plunger assembly 258 is configured to substantially sealinglyengage the diaphragm 216 and extend through a first orifice 294 of thediaphragm 216.

In some embodiments, the first plunger 266 comprises a first shank 268which terminates at a distal end as a first seat 270. The seat 270 isgenerally tapered or conical in shape and selectively engages a firstO-ring or seal ring 272 to selectively substantially seal or allow thefirst fuel to flow through a first orifice 274 of the chamber 242 and/orthe first input channel 236.

In certain embodiments, the tensioning of the first screw 254 allows forflow control of the first fuel at a predetermined first pressure orpressure range and selectively maintains the orifice 274 open so thatthe first fuel can flow into the chamber 242, into the output channel240 and out of the outlet 234 and into the intake pipe 122 of the heater10 for downstream combustion. If the first pressure exceeds a firstthreshold pressure, the first plunger seat 270 is pushed towards thefirst seal ring 272 and seals off the orifice 274, thereby terminatingfluid communication between the first input channel 236 (and the firstfuel source) and the chamber 242 of the housing 218.

In some embodiments, the first pressure or pressure range and the firstthreshold pressure are adjustable by the tensioning of the first screw254. In certain embodiments, the pressure selected depends at least inpart on the particular fuel used, and may desirably provide for safe andefficient fuel combustion and reduce, mitigate, or minimize undesirableemissions and pollution. In some embodiments, the first screw 254 may betensioned to provide a first pressure in the range from about 3 inchesof water column to about 6 inches of water column, including all valuesand sub-ranges therebetween. In some embodiments, the first threshold orflow-terminating pressure is about 3 inches of water column, about 4inches of water column, about 5 inches of water column, or about 6inches of water column. In certain embodiments, when the first inlet 230and the first input channel 236 are being utilized to provide a givenfuel, the second inlet 232 is plugged or substantially sealed.

In certain embodiments, the first pressure regulator 220 (and/or thefirst valve assembly 224) comprises a vent 290 or the like at the firstportion 212. The vent can be substantially sealed, capped, or covered bya dustproof cap or cover, often for purposes of shipping. The cover isoften removed prior to use of the regulator 120. In many embodiments,the vent 290 is in fluid communication with the bonnet 246 housing thespring 250 and may be used to vent undesirable pressure build-up and/orfor cleaning or maintenance purposes.

In certain embodiments, the second plunger assembly 260 generallycomprises a second diaphragm plate or seat 276 which seats the secondspring 252, a second washer 278 and a movable second plunger or valvestem 280 that extends into the housing 218 of the second portion 214.The second plunger assembly 260 substantially sealingly engages thediaphragm 216 and extends through a second orifice 296 of the diaphragm216.

In certain embodiments, the second plunger 280 comprises a second shank282 which terminates at a distal end as a second seat 284. The seat 284is generally tapered or conical in shape and selectively engages asecond O-ring or seal ring 286 to selectively substantially seal orallow the second fuel to flow through a second orifice 288 of thechamber 242 and/or the second input channel 238.

In certain embodiments, the tensioning of the second screw 256 allowsfor flow control of the second fuel at a predetermined second pressureor pressure range and selectively maintains the orifice 288 open so thatthe second fuel can flow into the chamber 242, into the output channel240 and out of the outlet 234 and into the intake pipe 122 of the heater10 for downstream combustion. If the second pressure exceeds a secondthreshold pressure, the second plunger seat 284 is pushed towards thesecond seal ring 286 and seals off the orifice 288, thereby terminatingfluid communication between the second input channel 238 (and the secondfuel source) and the chamber 242 of the housing 218.

In certain embodiments, the second pressure or pressure range and thesecond threshold pressure are adjustable by the tensioning of the secondscrew 256. In some embodiments, the second screw 256 may be tensioned toprovide a second pressure in the range from about 8 inches of watercolumn to about 12 inches of water column, including all values andsub-ranges therebetween. In some embodiments, the second threshold orflow-terminating pressure is about equal to 8 inches of water column,about 9 inches of water column, about 10 inches of water column, about11 inches of water column, or about 12 inches of water column. Incertain embodiments, when the second inlet 232 and the second inputchannel 238 are being utilized to provide a given fuel, the first inlet230 is plugged or substantially sealed.

In certain embodiments, the second pressure regulator 222 (and/or thesecond valve assembly 226) comprises a vent 292 or the like at the firstportion 212. The vent can be substantially sealed, capped or covered bya dustproof cap or cover. The vent 292 is in fluid communication withthe bonnet 248 housing the spring 252 and may be used to ventundesirable pressure build-up and/or for cleaning or maintenancepurposes and the like.

In some embodiments, when natural gas is the first fuel and propane isthe second fuel, the first pressure, pressure range and thresholdpressure are less than the second pressure, pressure range and thresholdpressure. Stated differently, in some embodiments, when natural gas isthe first fuel and propane is the second fuel, the second pressure,pressure range and threshold pressure are greater than the firstpressure, pressure range and threshold pressure.

Advantageously, the dual regulator 120, by comprising first and secondpressure regulators 220, 222 and corresponding first and second valvesor valve assemblies 224, 226, which are selectively and independentlyoperable facilitates a single heater unit being efficaciously used withdifferent fuel sources. This desirably saves on inventory costs, offersa retailer or store to stock and provide a single unit that is usablewith more than one fuel source, and permits customers the convenience ofreadily obtaining a unit which operates with the fuel source of theirchoice. The particular fuel pressure operating range is desirablyfactory-preset to provide an adaptable and versatile heater.

The pressure regulating device 120 can comprise a wide variety ofsuitably durable materials. These include, but are not limited to,metals, alloys, ceramics, plastics, among others. In one embodiment, thepressure regulating device 120 comprises a metal or alloy such asaluminum or stainless steel. The diaphragm 216 can comprise a suitabledurable flexible material, such as, but not limited to, various rubbers,including synthetic rubbers. Various suitable surface treatments andfinishes may be applied with efficacy, as needed or desired.

In certain embodiments, the pressure regulating device 120 can befabricated or created using a wide variety of manufacturing methods,techniques and procedures. These include, but are not limited to,casting, molding, machining, laser processing, milling, stamping,laminating, bonding, welding, and adhesively fixing, among others.

Although the regulator 120 has been described as being integrated in theheater 10, the regulator 120 is not limited to use with heating devices,and can benefit various other applications. Additionally, pressureranges and/or fuel-types that are disclosed with respect to one portionof the regulator 120 can also apply to another portion of the regulator120. For example, tensioning of either the first screw 254 or the secondscrew 256 can result in pressure ranges between about 3 inches of watercolumn and about 6 inches of water column or between about 8 inches ofwater column and about 12 inches of water column, in some embodiments.

As noted above, in certain embodiments, the regulator 120 is configuredto allow passage therethrough of either a first or a second fuel. Incertain embodiments, the first or the second fuel passes through theintake pipe 122 to the heater control valve 130.

With reference to FIG. 8, in certain embodiments, the heater controlvalve 130 includes the knob 132. The heater control valve 130 can becoupled with the intake pipe 122, the fuel supply pipe 124 and the ODSpipe 126. In certain embodiments, the heater control valve 130 iscoupled with the ODS thermocouple 182. In further embodiments, theheater control valve 130 comprises a temperature sensor 300.

In some embodiments, the heater control valve 130 allows a portion ofthe first or the second fuel to pass from the intake pipe 122 to thefuel supply pipe 124 and another portion to pass to the ODS pipe 126. Incertain embodiments, the amount of fuel passing through the heatercontrol valve 130 is influenced by the settings of the knob 132 and/orthe functioning of the thermocouple 182. In some embodiments, the knob132 is rotated by a user to select a desired temperature. Based on thetemperature selected by the user and the temperature sensed by thetemperature sensor 300, the heater control valve 130 can allow more orless fuel to pass to the fuel supply pipe 124.

Furthermore, as discussed below, when a pilot light of the ODS heats thethermal couple 182, a current is generated in the thermocouple 182. Incertain embodiments, this current produces a magnetic field within theheater control valve 130 that maintains the valve 130 in an openposition. If the pilot light goes out or is disturbed, and the currentflow is reduced or terminated, the magnetic field weakens or iseliminated, and the valve 130 closes, thereby preventing passagetherethrough of the first or the second fuel.

With reference to FIG. 9, in certain embodiments, the first or thesecond fuel allowed through the heater control valve 130 proceeds to thefluid flow controller 140. In certain embodiments, the controller 140comprises a housing 405, a first inlet 410, and a second inlet 420. Insome embodiments, the first inlet 410 is configured to couple with thefuel supply pipe 124 and the second inlet 420 is configured to couplewith the ODS pipe 126.

With reference to FIG. 10, in certain embodiments, the fluid flowcontroller 140 comprises a first fuel supply outlet 431, and a secondfuel supply outlet 432, a first ODS outlet 433, a second ODS outlet 434.In some embodiments, the fluid flow controller 140 further comprises afirst selector valve 441 and a second selector valve 442. In someembodiments, a first selector control or knob 443 is coupled to thefirst selector valve 441 and a second selector knob 444 is coupled tothe second selector valve 442.

With reference to FIG. 11, in some embodiments, one of the first andsecond selector valves 441, 442 can be rotated within the housing viathe first or second selector knob 443, 444, respectively. In someembodiments, the second selector valve 442 is closed and the firstselector valve 441 is opened such that fluid flowing through the fuelsupply pipe 124 proceeds to the first fuel supply outlet 431 and intothe first nozzle line 141 and fluid flowing through the ODS pipe 126proceeds to the first ODS outlet 433 and into the first ODS line 143. Inother embodiments, the first selector valve 441 is closed and the secondselector valve 442 is opened such that fluid flowing through the fuelsupply pipe 124 proceeds to the second fuel supply outlet 432 and intothe second nozzle line 142 and fluid flowing through the ODS pipe 126proceeds to the second ODS outlet 434 and into the second ODS line 144.Accordingly, in certain embodiments, the fluid flow controller 140 candirect a first fluid to a first set of pipes 141, 143 leading to thenozzle 160 and the ODS 180, and can direct a second fluid to a secondset of pipes 142, 144 leading to the nozzle 160 and the ODS 180.

With reference to FIG. 12, in certain embodiments, the nozzle 160comprises an inner tube 610 and an outer tube 620. The inner tube 610and the outer tube 620 can cooperate to form a body of the nozzle 160.In some embodiments, the inner tube 610 and the outer tube 620 areseparate pieces joined in substantially airtight engagement. Forexample, the inner tube 610 and the outer tube 620 can be welded, glued,secured in threaded engagement, or otherwise attached or secured to eachother. In other embodiments, the inner tube 610 and the outer tube 620are integrally formed of a unitary piece of material. In someembodiments, the inner tube 610 and/or the outer tube 620 comprises ametal.

As illustrated in FIG. 13, in certain embodiments, the inner tube 610and the outer tube 620 are elongated, substantially hollow structures.In some embodiments, a portion of the inner tube 610 extends inside theouter tube 620. As illustrated in FIGS. 13 and 14, in some embodiments,the inner tube 610 and the outer tube 620 can be substantially coaxialin some embodiments, and can be axially symmetric.

With continued reference to FIG. 13, in some embodiments, the inner tube610 comprises a connector sheath 612. The connector sheath 612 cancomprise an inlet 613 having an area through which a fluid can flow. Insome embodiments, the connector sheath 612 is configured to couple withthe second nozzle line 142, preferably in substantially airtightengagement. In some embodiments, an inner perimeter of the connectorsheath 612 is slightly larger than an outer perimeter of the secondnozzle line 142 such that the connector sheath 612 can seat snugly overthe second nozzle line 142. In some embodiments, the connector sheath612 is welded to the second nozzle line 142. In other embodiments, aninterior surface of the connector sheath 612 is threaded for couplingwith a threaded exterior surface of the second nozzle line 142. In stillother embodiments, the second nozzle line 142 is configured to fit overthe connector sheath 612.

In certain embodiments, the connector sheath 612 comprises a distalportion 614 that is configured to couple with the outer tube 620. Insome preferred embodiments, each of the distal portion 614 of the innertube 620 and a proximal portion 625 of the outer tube 620 comprisesthreads. Other attachment configurations are also possible.

In certain embodiments, the nozzle 160 comprises a flange 616 thatextends from the connector sheath 612. In some embodiments, the flange616 is configured to be engaged by a tightening device, such as awrench, which can aid in securing the inner tube 610 to the outer tube620 and/or in securing the nozzle 160 to the second nozzle line 142. Insome embodiments, the flange 624 comprises two or more substantiallyflat surfaces, and in other embodiments, is substantially hexagonal (asshown in FIGS. 12 and 14).

In further embodiments, the outer tube 620 comprises a shaped portion627 that is configured to be engaged by a tightening device, such as awrench. In some embodiments, the shaped portion 627 is substantiallyhexagonal. In certain embodiments, the shaped portion 627 of the outertube 620 and the flange 616 of the inner tube 610 can each be engaged bya tightening device such that the outer tube 620 and the inner tube 610rotate in opposite directions about an axis of the nozzle 160.

In certain embodiments, the inner tube 610 defines a substantiallyhollow cavity or pressure chamber 630. The pressure chamber 630 can bein fluid communication with the inlet 613 and an outlet 633. In someembodiments, the outlet 633 defines an outlet area that is smaller thanthe area defined by the inlet 613. In preferred embodiments, thepressure chamber 630 decreases in cross-sectional area toward a distalend thereof. In some embodiments, the pressure chamber 630 comprises twoor more substantially cylindrical surfaces having different radii. Insome embodiments, a single straight line is collinear with or runsparallel to the axis of each of the two or more substantiallycylindrical surfaces.

In some embodiments, the outer tube 620 substantially surrounds aportion of the inner tube 610. The outer tube 620 can define an outerboundary of a hollow cavity or pressure chamber 640. In someembodiments, an inner boundary of the pressure chamber 640 is defined byan outer surface of the inner tube 610. In some embodiments, an outersurface of the pressure chamber 640 comprises two or more substantiallycylindrical surfaces joined by substantially sloped surfacestherebetween. In some embodiments, a single straight line is collinearwith or runs parallel to the axis of each of the two or moresubstantially cylindrical surfaces.

In preferred embodiments, an inlet 645 and an outlet 649 are in fluidcommunication with the pressure chamber 640. In some embodiments, theinlet 645 extends through a sidewall of the outer tube 620. Accordingly,in some instances, the inlet 645 generally defines an area through whicha fluid can flow. In some embodiments, the direction of flow of thefluid through the inlet 645 is nonparallel with the direction of flow ofa fluid through the inlet 613 of the inner tube 610. In someembodiments, an axial line through the inlet 645 is at an angle withrespect to an axial line through the inlet 613. The inlet 645 can beconfigured to be coupled with the first nozzle line 141, preferably insubstantially airtight engagement. In some embodiments, an innerperimeter of the inlet 645 is slightly larger than an outer perimeter ofthe first nozzle line 141 such that the inlet 645 can seat snugly overthe first nozzle line 141. In some embodiments, the outer tube 620 iswelded to the first nozzle line 141.

In certain embodiments, the outlet 649 of the outer sheath 620 definesan area smaller than the area defined by the inlet 645. In someembodiments, the area defined by the outlet 649 is larger than the areadefined by the outlet defined by the outlet 613 of the inner tube 610.In some embodiments, the outlet 613 of the inner tube 610 is within theouter tube 620. In other embodiments, the inner tube 610 extends throughthe outlet 649 such that the outlet 613 of the inner tube 610 is outsidethe outer tube 620.

In certain embodiments, a fluid exits the second nozzle line 142 andenters the pressure chamber 630 of the inner tube 610 through the inlet613. The fluid proceeds through the outlet 633 to exit the pressurechamber 630. In some embodiments, the fluid further proceeds through aportion of the pressure chamber 640 of the outer tube 620 before exitingthe nozzle 160 through the outlet 649.

In other embodiments, a fluid exits the first nozzle line 142 and entersthe pressure chamber 640 of the outer tube 620 through the inlet 645.The fluid proceeds through the outlet 633 to exit the pressure chamber640 and, in many embodiments, exit the nozzle 160. In certainembodiments, a fluid exiting the second nozzle line 142 and travelingthrough the pressure chamber 630 is at a higher pressure than a fluidexiting the first nozzle line 141 and traveling through the pressurechamber 640. In some embodiments, liquid propane travels through thepressure chamber 630, and in other embodiments, natural gas travelsthrough the pressure chamber 640.

With reference to FIG. 15-17, in certain embodiments, the ODS 180comprises a thermocouple 182, a first nozzle 801, a second nozzle 802, afirst electrode 808, and a second electrode 809. In further embodiments,the ODS 180 comprises a first injector 811 coupled with the first ODSline 143 (see FIGS. 1 and 2) and the first nozzle 801 and a secondinjector 812 coupled with the second ODS line 144 (see FIGS. 1 and 2)and the second nozzle 802. In many embodiments, the first and secondinjectors 811, 812 are standard injectors as are known in the art, suchas injectors that can be utilized with liquid propane or natural gas. Insome embodiments, the ODS 180 comprises a frame 820 for positioning theconstituent parts of the ODS 180.

In some embodiments, the first nozzle 801 and the second nozzle 802 aredirected toward the thermocouple such that a stable flame exiting eitherof the nozzles 801, 802 will heat the thermocouple 182. In certainembodiments, the first nozzle 801 and the second nozzle 802 are directedto different sides of the thermocouple 182. In some embodiments, thefirst nozzle 801 and the second nozzle 802 are directed to oppositesides of the thermocouple 182. In some embodiments, the first nozzle 801is spaced at a greater distance from the thermocouple than is the secondnozzle 802.

In some embodiments, the first nozzle 801 comprises a first air inlet821 at a base thereof and the second nozzle 802 comprises a second airinlet 822 at a base thereof. In various embodiments, the first air inlet821 is larger or smaller than the second air inlet 822. In manyembodiments, the first and second injectors 811, 812 are also located ata base of the nozzles 801, 802. In certain embodiments, a gas or aliquid flows from the first ODS line 143 through the first injector 811,through the first nozzle 801, and toward the thermocouple 182. In otherembodiments, a gas or a liquid flows from the second ODS line 144through the second injector 812, through the second nozzle 802, andtoward the thermocouple 182. In either case, the fluid flows near thefirst or second air inlets 821, 822, thus drawing in air for mixing withthe fluid. In certain embodiments, the first injector 811 introduces afluid into the first nozzle 801 at a first flow rate, and the secondinjector 812 introduces a fluid into the second nozzle 802 at a secondflow rate. In various embodiments, the first flow rate is greater thanor less than the second flow rate.

In some embodiments, the first electrode 808 is positioned at anapproximately equal distance from an output end of the first nozzle 801and an output end of the second nozzle 802. In some embodiments, asingle electrode is used to ignite fuel exiting either the first nozzle801 or the second nozzle 802. In other embodiments, a first electrode808 is positioned closer to the first nozzle 801 than to the secondnozzle 802 and the second electrode 809 is positioned nearer to thesecond nozzle 802 than to the first nozzle 801.

In some embodiments, a user can activate the electrode by depressing theigniter switch 186 (see FIG. 2). The electrode can comprise any suitabledevice for creating a spark to ignite a combustible fuel. In someembodiments, the electrode is a piezoelectric igniter.

In certain embodiments, igniting the fluid flowing through one of thefirst or second nozzles 801, 802 creates a pilot flame. In preferredembodiments, the first or the second nozzle 801, 802 directs the pilotflame toward the thermocouple such that the thermocouple is heated bythe flame, which, as discussed above, permits fuel to flow through theheat control valve 130.

FIG. 18 illustrates another embodiment of the ODS 180′. In theillustrated embodiment, the ODS 180′ comprises a single electrode 808.In the illustrated embodiment, each nozzle 801, 802 comprises an firstopening 851 and a second opening 852. In certain embodiments, the firstopening 851 is directed toward a thermocouple 182′, and the secondopening 852 is directed substantially away from the thermocouple 182′.

In various embodiments, the ODS 180 provides a steady pilot flame thatheats the thermocouple 182 unless the oxygen level in the ambient airdrops below a threshold level. In certain embodiments, the thresholdoxygen level is between about 18 percent and about 18.5 percent. In someembodiments, when the oxygen level drops below the threshold level, thepilot flame moves away from the thermocouple, the thermocouple cools,and the heat control valve 130 closes, thereby cutting off the fuelsupply to the heater 10.

FIG. 19 illustrates another embodiment of a heater 10′. In certainembodiments, the heater 10′ and/or one or more components thereof issimilar to the heater 10 and/or one or more components thereof,described above, thus similar features are identified with similar,primed reference numerals. Accordingly, as with the heater 10, in someembodiments, the heater 10′ is a vent-free infrared heater, a vent-freeblue flame heater, or some other variety of heater, such as a directvent heater. In certain embodiments, the heater 10′ comprises a stove,fireplace, gas log set, or gas log insert. Other configurations are alsopossible for the heater 10′. In many embodiments, the heater 10′ isconfigured to be mounted to a wall or a floor or to otherwise rest in asubstantially static position. In other embodiments, the heater 10′ isconfigured to move within a limited range. In still other embodiments,the heater 10′ is portable.

In certain embodiments, the heater 10′ comprises a housing 20′. Thehousing 20′ can enclose or partially enclose components of the heater10′ including, for example, a regulator 120′. The regulator 120′preferably is coupled with a primary fuel line 122′. The primary line122′, or any other fuel delivery line described herein, can comprise aconduit, pipe, channel, or any other suitable structure for directingfluid flow. The primary line 122′ can be coupled with a heater controlvalve or control valve assembly 1000, which in some embodiments,includes a dial or knob 1002. In some embodiments, the knob 1002 isconfigured to be manually manipulated by a user.

In many embodiments, the control valve assembly 1000 is coupled to afuel supply line 124′ and an oxygen depletion sensor (ODS) line 126′,each being capable of being coupled with a fluid flow controller 140′.In some embodiments, the fluid flow controller 140′ is coupled with afirst nozzle line 141′, a second nozzle line 142′, an ODS line 143′, anda second ODS line 144′. In some embodiments, the first and second nozzlelines 141′, 142′ are coupled with a nozzle 160′, and the first and thesecond ODS lines 143′, 144′ are coupled with an ODS 180′. In someembodiments, the ODS 180′ comprises a thermocouple 182′ and an igniterline 184′ that can be coupled to the control valve assembly 1000.Furthermore, in some embodiments, the heater 10′ comprises a combustionchamber or burner 190′ that may be configured to receive fuel from thenozzle 160′. Thus the heater 10′ can be generally similar to the heater10 described above with differences related to the control valveassembly 1000.

Although the control valve assembly 1000 is described herein in thecontext of the heater 10′, which can be configured to operate usingfluid fuel received from either a first source or a second source, it isappreciated that certain embodiments of the valve assembly 1000 arecompatible with a variety of heat producing devices, including thoseconfigured to operate on only a single type of fuel. Some embodiments ofthe valve assembly 1000 are of particular utility with a variety of gasheaters and a variety of gas fireplace devices, such as gas log sets andfireplace inserts, whether of a dual-fuel-source or a single-fuel sourcevariety.

With continued reference to FIG. 19 in some embodiments, the ODS 180′can be positioned on or near the burner 190′, and can produce a pilotflame in sufficiently close proximity to the burner 190′ to ignite fueldelivered to the burner 190′. The ODS 180′ can also comprise anelectrode 808′ such as the electrode 808 described above. In someembodiments, the electrode 808′ is configured to ignite fuel deliveredto the ODS 180′ and thus start the pilot flame. In some embodiments, theelectrode 808′ is sufficiently close to the burner 190′ that it canignite fuel delivered to the burner 190′. In the illustrated embodiment,the ODS 180′ is configured to provide a pilot light for combusting fueldelivered to the burner 190′, and includes an electrode 808′ coupled tothe control valve assembly 1000 via the igniter line 184′, as discussedbelow.

With reference to FIG. 20, in certain embodiments, the control valveassembly 1000 includes a housing 1004, which can define a number ofinlets and outlets. In some embodiments, the housing 1004 defines aninlet 1006 that is configured to receive fuel from the primary line122′. The inlet 1006 can comprise any suitable interface for couplingwith the primary line 122′, and in some embodiments, defines a tube-likeprojection having internal or external threading. The housing 1004 canfurther define an ODS outlet 1008 configured to couple with and todeliver fuel to the ODS line 126′.

In certain embodiments, the housing 1004 defines a first burner outlet1010 and a second burner outlet 1012. In some embodiments, the firstburner outlet 1010 is coupled with the fuel supply line 124′ and thesecond burner outlet 1012 is plugged or capped in any suitable manner.In other embodiments, the second burner outlet 1012 is coupled with thefuel supply line 124′ and the first burner outlet 1012 is plugged orcapped. Advantageously, such an arrangement of the housing 1004 canprovide the control valve assembly 1000 with versatility such that thecontrol valve assembly 1000 can be included in any of a variety ofheaters having different piping configurations. Additionally, theoutlets 1010 and 1012 can provide a variety of plumbing options toprovide the shortest and/or most convenient plumbing path within a givenheater 10′. The control valve assembly 1000 can thus reducemanufacturing costs and inventory demands. In other embodiments, thecontrol valve assembly 1000 comprises either a first burner outlet 1010or a second burner outlet 1012. The first and/or second burner outlets1010, 1012 can be oriented in any suitable position for directing fuelfrom the control valve assembly 1000. In the illustrated embodiment, thefirst burner outlet 1010 is open and is configured to couple with thefuel supply line 124′, and the second burner outlet 1012 is plugged withan insert 1013, which can comprise a bolt or other threaded piece, forexample.

In certain embodiments, the assembly 1000 includes a temperatureregulator 1020. The regulator 1020 can be coupled with the housing 1004in any suitable manner, and in some embodiments, is mounted to a plate1022 that is mounted to the housing 1004. As further described below,the regulator 1020 can include and/or be coupled with a thermostat forregulating the temperature of the environment surrounding the heater10′. In some embodiments, the temperature regulator 1020 includes apower interface 1025 for coupling with any suitable power source. Inother embodiments, the temperature regulator 1020 includes its own powersource, such as, for example, a battery.

In some embodiments, the assembly 1000 includes an igniter 1030, whichcan include a sensor 1032. The igniter 1030 can comprise an intermittentigniter coupled with the electrode 808′ via the igniter line 184′. Theigniter 1030 is preferably capable of repeatedly firing the electrode808′ when the sensor 1032 is activated, as discussed further below. Incertain embodiments, the sensor 1032 comprises a button that isrelatively sensitive to pressure actuation (e.g., physical contact) suchthat even relatively slight contact with the sensor 1032 results inmultiple firings of the electrode 808′. In other embodiments, the sensor1032 comprises a magnetometer or some other suitable sensor that candetect movement of an object without physical contact with the object.The igniter 1030 can be coupled to the housing 1004 via a mountingbracket 1035, and in some embodiments, is substantially fixed relativeto the housing 1004.

In certain embodiments, the assembly 1000 comprises an extension 1040.In some embodiments, the extension 1040 is substantially concealed by aportion of the housing 20′ of the heater 10′ such that the extension1040 is not readily visible from outside of the assembled heater 10′.The extension 1040 can be integrally formed with or otherwise coupledwith an actuator, pin, rod, or shaft 1045. In some embodiments, theextension 1040 extends radially from the shaft 1045. In someembodiments, the shaft 1045 is coupled with the selector knob 1002.

In certain embodiments, the extension 1040 is substantially disk-shaped,and can have a radius larger than the distance between an axial centerof the shaft 1045 and the sensor 1032 of the igniter 1030. Accordingly,in some embodiments, the extension 1040 is configured to contact thesensor 1032 and activate the igniter 1030 when the knob 1002 isdepressed, regardless of the rotational orientation of the knob 1002, asfurther described below.

With reference to FIG. 21, the housing 1004 can define a plurality offluid conduits, paths, pathways, or passageways. In various embodiments,the housing 1004 defines a primary passageway 1102 in fluidcommunication with the inlet 1006, an ODS passageway 1104 in fluidcommunication with the ODS outlet 1008, a first burner passageway 1106in fluid communication with the first and/or second burner outlets 1010,1012, and/or a second burner passageway 1108 in fluid communication withthe first and/or second burner outlets 1010, 1012. The housing 1004 canalso define a chamber 1110 from which one or more of the passageways1102, 1104, 1106, 1108 extend.

In certain embodiments, the control valve assembly 1000 includes one ormore valves configured to control fuel flow through one or more of thepassageways 1102, 1104, 1106, 1108. As used herein, the term valve is abroad term used in its ordinary sense, and can include, withoutlimitation, a device or structure configured to permit fluid flow in oneor more directions and/or to substantially prevent fluid flow in one ormore directions, and can further include structures capable of beingpositioned in two or more operational states such that, in a firststate, fluid flow is permitted and/or substantially prevented in one ormore different directions than is permitted and/or substantiallyprevented in a second state. The control valve assembly 1000 can includea primary valve 1118, which in some embodiments, is configured tocontrol fuel flow into the control valve assembly 1000 in response toinput from the thermocouple 182′, as further discussed below. In someembodiments, the control valve assembly 1000 includes a regulator valve1120 configured to control fuel flow through the second burnerpassageway 1108, as further discussed below. In some embodiments, one ormore of the primary valve 1118 and the regulator valve 1120 functions asa shutoff valve, and can thus be configured to prevent fluid flow undercertain circumstances.

In some embodiments, the control valve assembly 1000 includes acontroller valve 1116 that preferably is configured to be movable to avariety of different orientations or operational states. In someembodiments, the controller valve 1116 comprises a valve body 1124configured to be received in the chamber 1110 defined by the housing1004. In some embodiments, the valve body 1124 comprises a substantiallyfrustoconical lower section 1126, and can be complementary to an innerwall 1128 of the housing 1004 that defines at least a portion of thechamber 1110. Accordingly, in some embodiments, the valve body 1124forms a substantially fluid-tight seal with the inner wall 1128 of thehousing 1004. Shapes and complementarities other than frustoconical arealso possible for the valve body 1124 and the inner wall 1128. Forexample, in some embodiments, the valve body 1124 and the inner wall1128 are each substantially cylindrical. In some embodiments, alubricant is included between the valve body 1124 and the inner wall1128 to permit the valve body 1124 to move relatively freely withrespect to the housing 1004. The valve body 1124 can be configured torotate relative to the housing 1004 so as to selectively permit fuel toflow from the inlet 1006 to one or more of the outlets 1008, 1010, and1012.

In some embodiments, the valve body 1124 defines a hollow centralportion 1130 and may further define a variety of ports (see FIGS. 23-25)that pass through the lower portion 1126 to control fuel flow throughthe control valve assembly 1000. The valve body 1124 also preferablycomprises an upper portion 1132 that can be substantially interior to acap 1134 attached to an upper end of the housing 1004 in an assembledcontrol valve assembly 1000. Located within the upper portion 1132 ofthe valve body 1124 preferably is a biasing member 1136 that isconfigured to bias the shaft 1045 upwards relative to the cap 1134. Thebiasing member 1136 can comprise a spring or other resilient element. Insome embodiments, a rod 1140 extends downward from a lower end of theshaft 1045. The rod 1140 can extend through the valve body 1124 and, incertain conditions, open the primary valve 1118 when the shaft 1045 ismoved downward, as described below.

References to spatial relationships, such as upper, lower, downward,etc., are made herein merely for convenience in describing embodimentsdepicted in the figures, and should not be construed as limiting. Forexample, such references are not intended to denote a preferredgravitational orientation of the control valve assembly 1000.

In some embodiments, fuel flow from the inlet 1006 and through thepassageway 1102 preferably is controlled by the primary valve 1118,which in some embodiments, comprises a solenoid coupled with thethermocouple 182′. The chamber 1110 of the housing 1004 can be in fluidcommunication with the hollow portion 1130 of the valve body 1124.Accordingly, in some embodiments, fuel can pass from the chamber 1110through the lower portion 1126 of the valve body 1124 and may enter oneor more of the ODS passageway 1104, the first burner passageway 1106,and the second burner passageway 1108, depending on the orientation ofthe valve body 1124.

The shaft 1045 can assume any of a variety of suitable shapes orconfigurations, and can comprise a column, rod, stem, stock. In certainembodiments, the shaft 1045 includes an upper portion 1145 that extendsthrough the extension 1040 and is coupled with the knob 1002. In someembodiments, the shaft 1045 defines a protrusion (see FIG. 22) thatextends from a lower end thereof and is configured to fit within alongitudinal slit (not shown) defined by the upper portion 1132 of thevalve body. Accordingly, in some embodiments, the shaft 1045 is capableof axial movement relative to the valve body 1124 and can rotate thevalve body 1124 at any point within the range of axial movement of theshaft 1045. In some embodiments, the shaft 1045 can move axially betweena resting, natural, or first state and a displaced or second state. Incertain embodiments, when the shaft 1045 is in the resting state, thebiasing member 1136 is substantially relaxed or undisturbed, and whenthe shaft 1045 is in the displaced state, the biasing member is deformedor compressed, and is thus biased to return the shaft 1045 to theresting state.

With reference to FIG. 22A, in some embodiments, the shaft 1045 definesthe protrusion 1156 and the cap 1134 defines a plurality of shelves orridges 1160 and recesses, channels, or depressions 1168 configured tointeract with the protrusion 1156. In the illustrated embodiment, thecap 1134 defines four ridges 1160 a-d separated by four depressions 1168a-d. More or fewer ridges 1160 and depressions 1168 are possible. Incertain embodiments, each depression 1168 a-d corresponds with adifferent operational state of the valve assembly 1000, as describedbelow. For example, in some embodiments, the depression 1168 acorresponds with an “off” operational configuration, the depression 1168b corresponds with a “pilot” operational configuration, the depression1168 c corresponds with an “automatic” operational configuration, andthe depression 1168 d corresponds with a “manual” configuration, whichare described below. In further embodiments, the ridge 1160 c alsocorresponds with the “automatic” operational configuration and/or theridge 1160 d corresponds with the “manual” operational configuration.Other configurations of the cap 1134 and the shaft 1045 are alsopossible.

In some embodiments, each of the depressions 1168 a-d is similarly sizedand shaped, and can be configured to provide relatively littlerotational freedom to the shaft 1045 when the protrusion 1156 is withinthe depressions 1168 a-d. In certain embodiments, the shaft 1045 is inthe displaced state when it is moved downward relative to the cap 1134and out of one of the depressions 1168 a-d. Accordingly, when the shaft1045 is in the displaced state, the protrusion 1156 can pass under oneor more of the ridges 1160 a-d. The shaft 1045 can then be urged upwardtoward the resting state by the biasing member 1136 such that theprotrusion 1156 is again located within one of the depressions 1168 a-d.Accordingly, in some embodiments, the shaft 1045 is naturally in theresting state, due to the influence of the biasing member, with theprotrusion 1156 located in one of the depressions 1168 a-d, and theshaft 1045 is moved to a displaced state in order to rotate the shaft1045 and the valve body 1124. As discussed below, in certainembodiments, the igniter 1030 is activated when the shaft 1045 is movedto the displaced state and is deactivated when the controller valve 1116is moved to the resting state.

As illustrated in FIG. 22B, in an alternative embodiment, the cap 1134defines four ridges 1160 e-h separated by four depressions 1168 e-h. Insome embodiments, the depression 1168 e corresponds with the “off”operational configuration, the depression 1168 f corresponds with the“pilot” operational configuration, the depression 1168 g correspondswith the “automatic” operational configuration, and the depression 1168g corresponds with the “manual” configuration.

In some embodiments, the depressions 1168 e and 1168 f are similarlysized and shaped, and can be narrower than the depressions 1168 g and1168 h. The depressions 1168 e and 1168 f can be sized and shaped so asto provide relatively little rotational freedom to the shaft 1045 whenthe protrusion 1156 is within the depressions 1168 e, f. In contrast,the depressions 1168 g and 1168 h can be sized so as to provide theshaft 1045 with a relatively larger amount of rotational freedom whenthe protrusion 1156 is within the depressions 1168 g, h.

In some embodiments, a center of each depression 1168 e-h is offset fromthe center of each neighboring depression 1168 e-h by approximately 90degrees. In other embodiments, the depressions 1168 e-h are spaced fromeach other by one or more other angular amounts. In certain embodiments,the cap 1134 defines a stop 1169 which can extend downward from theridge 1160 e and prevent movement of the protrusion 1156 greater thanabout 360 degrees.

With reference again to FIG. 21, the illustrated control valve assembly1000 is shown in a first operational orientation or configuration,referred to herein for convenience, and not by limitation, as the “off”operational configuration. In the illustrated embodiment, the valve body1124 is positioned such that none of the ports through the lower portion1126 are aligned with the passageways 1104, 1106, and 1108, thussubstantially preventing fluid communication between the chamber 110 andthe passageways 1104, 1106, and 1108. In many embodiments, the primaryvalve 1118 forms a substantially fluid-tight seal with a ledge definedby the housing 1004, thus preventing fluid communication between thepassageway 1102 and chamber 1110. In the illustrated embodiment, thecontroller valve 1116 is in the resting state with the shaft 1045 biasedupward by the biasing member 1136 such that the protrusion 1156 islocated in the depression 1168 a in the embodiment shown in FIG. 22A or1168 e in the embodiment shown in FIG. 22B, and the extension 1040 isspaced from the sensor 1032 of the igniter 1030. Accordingly, in certainembodiments, fuel is substantially prevented from entering the valveassembly 1000 and the igniter 1030 is in an inactivated state when thevalve assembly 1000 is in the “off” configuration.

FIG. 23 illustrates an embodiment of the control valve assembly 1000 inanother configuration, referred to herein for convenience, and not bylimitation, as the “pilot” configuration. In certain embodiments, theODS 180′ can be ignited when the valve assembly 1000 is in the “pilot”configuration. As mentioned above in the particular illustratedembodiment the ODS 180′ also serves as the pilot light. In otherembodiments the pilot light and the ODS may comprise separateassemblies.

In certain embodiments, the shaft 1045 is moved downward relative to thecap 1134 to the displaced state in order to rotate the shaft 1045 fromthe “off” orientation. In some embodiments, as the shaft 1045 is rotatedrelative to the cap 1134, the extension 1040 continuously contacts thesensor 1032 and thus continuously activates the igniter 1030. In someembodiments, the igniter 1030 intermittently activates the electrode808′ via the igniter line 184′. The electrode 808′ thus combusts anyfuel delivered to the ODS 180′. When the shaft 1045 is in the displacedstate, the rod 1140 preferably opens the primary valve 1118 such thatthe primary passageway 1102 is placed in fluid communication with thechamber 1110.

In some embodiments, by rotating the shaft 1045 to the “pilot”configuration, an ODS hole, opening, aperture, or port 1176 defined bythe valve body 1124 is aligned with the ODS passageway 1104.Accordingly, in this configuration, fuel can flow into the inlet 1006,through the chamber 1110, through the ODS port 1176, through the ODSpassageway 1104, and through the ODS outlet 1008 to the ODS 180′. Insome embodiments, the ODS port 1176 extends through a substantialportion of the perimeter of the valve body 1124 such that the port 1176maintains communication between the chamber 1110 and passageway 1104 asthe valve body 1124 is rotated among a number of different orientations,such as, for example, among the “pilot” orientation, the “manual”orientation, and/or the “automatic” orientation. In some embodiments,the port 1176 is substantially ovoid. Accordingly, the valve body 1124can advantageously permit fluid to flow to the ODS 180′ as a userselects among a variety of operational states of the control valveassembly 1000, thereby maintaining a pilot flame.

In some embodiments, to ignite a pilot flame, the knob 1002 isdepressed, which displaces the extension 1040 downward. The extension1040 can in turn activate the igniter 1030, and thus activate theelectrode 808′. Furthermore, in some embodiments, as the knob 1002 isdepressed, the primary valve 1118 is manually held open by the rod 1140until the thermocouple 182′ generates sufficient current to maintain theprimary valve 1118 in an open configuration. While the knob 1002 isdepressed in order to place the controller valve 1116 in the “pilot”position, fuel flowing to the ODS 180′ is ignited via the intermittentignition provided by the igniter 1030. Certain embodiments are thusparticularly advantageous in that a user activates the igniter 1030 inorder to rotate the valve body 1124 and allow fuel to pass through thecontrol valve assembly 1000, which can thus prevent un-ignited fuel fromundesirably entering the environment. In some embodiments, if the knob1002 is released before the thermocouple 182′ has been heated by asufficient amount to keep the primary valve 1118 open, the primary valve1118 closes, thus cutting off the delivery of fuel to the ODS 180′.

In certain embodiments, as fuel is delivered to the ODS 180′, thethermocouple 182′ is heated and generates an electrical current that isdelivered to the primary valve 1118, which maintains the valve 1118 inan open configuration. In other embodiments, the primary valve 1118responds to some other electrical quantity communicated from the ODS180′, such as, for example, a voltage.

FIG. 24 illustrates an embodiment of the control valve assembly 1000 inanother configuration, referred to herein for convenience, and not bylimitation, as a “manual” configuration. In some embodiments, the knob1002 is depressed and then rotated to place the control valve assembly1000 in the “manual” configuration. As described above, when the knob1002 is depressed the extension 1040 preferably activates the igniter1030, which in turn intermittently ignites the electrode 808′. In someembodiments, the valve body 1124 is rotated such that a burner port 1178aligns with the first burner passageway 1106 and thus allows fuel topass from the chamber 1110, through the passageway 1106, and through thefirst burner outlet 1010.

As previously discussed, the ODS port 1176 preferably is configured suchthat the port 1176 maintains communication between the chamber 1110 andthe passageway 1104 as the valve body 1124 transitions between the“pilot” configuration and the “manual” configuration. Although in theillustrated embodiment the port 1176 maintains communication between thechamber 1110 and the passageway 1104 as the valve assembly 1000transitions among various operational states, other suitableconfigurations are also possible.

The burner port 1178 preferably is configured to permit a range of fluidflow through the passageway 1106. As the valve body 1124 is rotated, thedegree of alignment of the burner port 1178, which is substantiallycircular in some embodiments, with the passageway 1106 can change suchthat relatively more or less fuel is permitted into the passageway 1106.For example, in the embodiment shown in FIG. 22A, a portion of theburner port 1178 can be aligned with an opening into the passageway 1106as the protrusion 1156 rests on the ridge 1160 d. The portion of theburner port 1178 that is aligned with the passageway 1106 can increaseas the protrusion is rotated toward the depression 1168 d. In someembodiments, the burner port 1178 and the passageway are maximallyaligned when the protrusion 1156 rests within the depression 1168 d.

Alternatively, in the embodiment shown in FIG. 22B, the degree ofalignment of the burner port 1178 and the passageway 1106 can beadjusted as the protrusion 1156 retained in the relatively depression1168 h. In some embodiments, the degree of alignment is relatively small(e.g., minimal) at one end of the depression 1168 h, and is relativelylarge (e.g., maximal) at another end of the depression 1168 h. Incertain advantageous embodiments, altering the amount of fuel flowthrough the passageway can adjust the height of a flame produced at theburner 190′.

As described above with respect to the “pilot” configuration, in someadvantageous embodiments, the igniter 1030 is activated as the valveassembly 1000 is placed in the “manual” configuration. Such anarrangement can have significant advantages over other arrangements inwhich activating an igniter and selecting an operational mode of a valveassembly can be performed separately. For example, in some valveassemblies, a user can depress a knob to open a cutoff valve that isoperatively coupled with an ODS. Ordinarily the user depresses the knobwith one hand to open fuel flow to a burner, and activates an igniterwith another hand to combust the fuel delivered to the burner. Valveassemblies that permit a user to allow any amount of fuel to flow to theburner before igniting the fuel can allow undesirable amounts ofun-ignited fuel into the environment. Furthermore, a two-step assemblyof this sort can be inconvenient for users who wish to operate thesystem into which the valve assembly is integrated, but who may haveonly one hand free.

Furthermore, such systems can permit un-ignited fuel to pass through avalve assembly in a manner that is less apparent to many users. In somesystems, a user normally depresses the knob of a control valve to permitfuel flow therethrough, separately ignites fuel permitted through thevalve, and waits until a cut-off valve coupled with a thermocouple isheated sufficiently before releasing the knob. When the thermocouple issufficiently hot, the cut-off valve permits continuous fuel flow to theburner, and when the thermocouple is relatively cooler, the cut-offvalve prevents fuel flow to the burner.

However, in some embodiments, after the thermocouple has been heated fora period and the fuel flow to the burner is manually turned off by auser, the cut-off valve remains open until the thermocouple has cooleddown. In some instances, the cooling period between manual fuel cut-offand the shutting of the cut-off valve is about 40 to 45 seconds.Accordingly, if a user were to manually open the control valve duringthis cooling period and release the knob, un-ignited fuel could escapeinto the environment until the thermocouple cooled sufficiently to shutthe cut-off valve. Such a result could be contrary to a user'sunderstanding of the usual operation of the valve assembly, and coulddisadvantageously cause confusion for the user and/or present possiblehazards. As previously discussed, certain advantageous embodiments ofthe control valve assembly 1000 can substantially eliminate theforegoing drawbacks.

FIG. 25 illustrates the control valve assembly 1000 in anotheroperational configuration, referred to herein for convenience, and notby limitation, as the “automatic” configuration. As with the “pilot” and“manual” configurations described above, in some embodiments, the knob1002 is depressed and rotated to the “automatic” orientation. Rotatingthe knob 1002 and, in some embodiments, the shaft 1045 preferablyrotates the valve body 1124 so as to align a port 1180 with thepassageway 1108 and align the ODS port 1176 with the ODS passageway1104. In some embodiments, the port 1180 resembles the port 1178, andcan be substantially circular. Other configurations are also possible.The port 1180 can provide fluid communication between the chamber 1110and the passageway 1108, and can permit fuel to flow through thepassageway 1108 and the first burner outlet 1010. Additionally, in someembodiments, the port 1178 (see FIG. 24) is substantially closed whenthe valve assembly 1000 is in the “automatic” configuration such thatfuel is directed out of the valve body 1124 only through the ports 1176and 1180.

In some embodiments, the temperature regulator 1020 is configured toselectively seal the passageway 1108, and substantially prevent fuelflow therethrough, via the regulator valve 1120. For example, in someembodiments, the regulator valve 1120 is configured to seal a corridor1195 of the passageway 1108. In some embodiments, the temperatureregulator 1020 comprises a thermostat 1190 (shown schematically), whichcan be electrically coupled with a solenoid. The thermostat 1190 cancomprise any suitable thermostat known in the art or yet to be devised.In some embodiments, the thermostat 1190 is configured to be adjustedvia a remote-controller. The thermostat 1190 can be powered via anysuitable power source, such as an electrical outlet or a battery, forexample.

In some embodiments, the regulator valve 1120 is triggered when thethermostat 1190 detects a given environmental temperature and sends asignal to the regulator valve 1120. In some embodiments, the regulatorvalve 1120 seals the corridor 1195 when the thermostat 1190 detects afirst temperature. In further embodiments, the regulator valve 1120opens the corridor 1195 when the thermostat detects a second temperaturethat is lower than the first temperature. In some embodiments, theregulator valve 1120 repeatedly opens and closes the corridor 1195 asthe first and second temperatures are detected.

As noted above, in some embodiments, the port 1176 is open when thecontrol valve assembly 1000 is in the “automatic” configuration suchthat a pilot flame at the ODS in sustained when the regulator valve 1120closes. Accordingly, when the regulator valve 1120 opens again andpermits fuel to flow to the burner 190′, the fuel is ignited by thepilot flame.

As with the “manual” configuration, in some embodiments, the valve body1124 can be rotated when in the “automatic” configuration to adjust thedegree of alignment of the port 1180 with the passageway 1108. Forexample, in some embodiments, the port 1180 and the passageway 1108 areslightly aligned as the protrusion 1156 of the shaft 1045 contacts theridge 1160 c, and are substantially completely aligned as the protrusion1156 is retained in the depression 1168 c (see FIG. 22A). In otherembodiments, the protrusion 1156 of the shaft 1045 is retained in therelatively wide depression 1168 g (see FIG. 22B), which can permitrotation of the shaft 1045 and valve body 1124. Accordingly, the valvebody 1124 can permit varying amounts of fuel to flow to the burner 190′and can thus alter the size of a flame produced at the burner 190′. Incertain advantageous embodiments, a user can select a desiredenvironmental temperature via the temperature regulator 1020, and canalso adjust the flame size at the burner 190′. As a result, when theassembly 1000 is in the “automatic” configuration, the user canindependently select a flame size and environmental temperature tocreate a desired ambiance, in some embodiments.

Although particular embodiments of the control valve assembly 1000 havebeen described as including solenoid valves, other suitable valves mayalso be used. Such other suitable valves may comprise, for example,pneumatic valves, hydraulic valves or any other suitable valve.

Reference throughout this specification to “one embodiment” or “anembodiment” means that a particular feature, structure or characteristicdescribed in connection with the embodiment is included in at least oneembodiment. Thus, appearances of the phrases “in one embodiment” or “inan embodiment” in various places throughout this specification are notnecessarily all referring to the same embodiment. Furthermore, theparticular features, structures or characteristics of any embodimentdescribed above may be combined in any suitable manner, as would beapparent to one of ordinary skill in the art from this disclosure, inone or more embodiments.

Similarly, it should be appreciated that in the above description ofembodiments, various features of the inventions are sometimes groupedtogether in a single embodiment, figure, or description thereof for thepurpose of streamlining the disclosure and aiding in the understandingof one or more of the various inventive aspects. This method ofdisclosure, however, is not to be interpreted as reflecting an intentionthat any claim require more features than are expressly recited in thatclaim. Rather, as the following claims reflect, inventive aspects lie ina combination of fewer than all features of any single foregoingdisclosed embodiment. Thus, the claims following the DetailedDescription are hereby expressly incorporated into this DetailedDescription, with each claim standing on its own as a separateembodiment.

1. A control valve assembly for gas heaters and gas fireplace devices,the assembly comprising: a housing defining: an inlet for accepting fuelfrom a fuel source; a first outlet for delivering fuel to an oxygendepletion sensor; and a second outlet for delivering fuel to a burner; avalve body configured to selectively provide fluid communication betweenthe inlet and one or more of the first outlet and the second outlet; anactuator configured to move the valve body relative to the housing, theactuator configured to transition between a resting state and adisplaced state; an igniter comprising a sensor, the igniterelectrically coupled with an electrode and configured to repeatedlyactivate the electrode when the sensor senses that the actuator is inthe displaced state; and a first shutoff valve electrically coupled withthe oxygen depletion sensor and configured to operate in response to anelectrical quantity communicated by the oxygen depletion sensor.
 2. Theassembly of claim 1, wherein the actuator is moved to the displacedstate in order to move the valve body from a first orientation in whichsubstantially no fluid communication is permitted between the inlet andthe first and second outlets and a second orientation in which the inletis in fluid communication with one or more of the first and secondoutlets.
 3. The assembly of claim 2, further comprising: a cap having aplurality of ridges and depressions; and a biasing member configured tourge the actuator toward the resting state; wherein the actuator definesa protrusion that is retained within one of the plurality of depressionswhen the actuator is in the resting state, the protrusion beingprevented from rotational movement by a set of adjacent ridges, andwherein a bias provided by the biasing member is overcome when theactuator is moved to the displaced state, thereby permitting theprotrusion to rotate past one or more of the ridges.
 4. The assembly ofclaim 2, wherein the electrode is positioned in close proximity to theburner such that fuel delivered to the burner via the second outlet isignited when the actuator is in the displaced state.
 5. The assembly ofclaim 4, wherein the electrode ignites fuel delivered to the oxygendepletion sensor.
 6. The assembly of claim 1, said actuator comprising ashaft comprising an extension, the extension configured to activate thesensor of the igniter when the actuator is in the displaced state. 7.The assembly of claim 6, wherein the sensor is positioned at asubstantially fixed distance from an axial center of the actuator, andwherein the extension is configured to contact the sensor when theactuator is rotated about said axial center by any amount.
 8. Theassembly of claim 1, wherein the sensor of the igniter is pressureactivated.
 9. The assembly of claim 1, wherein the valve body and theactuator comprise separate pieces.
 10. The assembly of claim 1, whereinthe housing further defines a first passageway and a second passagewaybetween the valve body and the second outlet, the valve body configuredto permit fluid communication between the inlet and the second outletvia either the first passageway or the second passageway.
 11. Theassembly of claim 10, further comprising a second shutoff valveconfigured to selectively prevent fluid communication between the valvebody and the second outlet via the first passageway.
 12. The assembly ofclaim 11, wherein the second shutoff valve comprises a solenoid inelectrical communication with a thermostat.
 13. The assembly of claim10, wherein the valve body is configured to selectively permit a rangeof fuel flow through the first passageway such that a height of a flameproduced at the burner is adjustable.
 14. The assembly of claim 13,wherein the first passageway defines a first opening and the valve bodydefines a second opening, wherein the first and second openings areconfigured to align with each other by varying amounts in order topermit said range of fuel flow through the first passageway.
 15. Acontrol valve assembly for gas heaters, gas log inserts and gasfireplaces, the assembly comprising: a housing defining: an inlet foraccepting fuel from a fuel source; a first outlet for delivering fuel toan oxygen depletion sensor; a second outlet for delivering fuel to aburner; a first fuel path in fluid communication with the second outlet;and a second fuel path in fluid communication with the second outlet; avalve body configured to selectively provide fluid communication betweenthe inlet and one or more of the first outlet and the second outlet, thevalve body configured to provide fluid communication between the inletand the second outlet via either the first fuel path or the second fuelpath; a first shutoff valve electrically coupled with the oxygendepletion sensor and configured to operate in response to an electricalquantity communicated by the oxygen depletion sensor; and a secondshutoff valve configured to selectively prevent fluid communicationbetween the valve body and the second outlet via the first fuel path.16. The assembly of claim 15, wherein the valve body is configured toselectively provide fluid communication between the inlet and the firstand second outlets.
 17. The assembly of claim 15, wherein the secondshutoff valve comprises a solenoid in electrical communication with athermostat.
 18. The assembly of claim 15, wherein the valve body or adial physically coupled with the valve body is configured to be manuallymanipulated such that an amount of fuel flow permitted through the firstfuel path is alterable and a height of a flame produced at the burner isvariable.
 19. The assembly of claim 18, wherein the second shutoff valvecomprises a solenoid in electrical communication with a thermostat. 20.The assembly of claim 18, wherein the first fuel path defines a firstopening and the valve body defines a second opening, the first andsecond openings configured to align with each other by varying amountsin order to alter said amount of fuel flow permitted through the firstfuel path.
 21. The assembly of claim 15, further comprising an igniterelectrically coupled with an electrode, the igniter configured torepeatedly activate the electrode as the valve body transitions amongoperational states.